Air-conditioning grill system

ABSTRACT

The present invention is generally directed to an apparatus and method for providing a single-size register grill system. In one aspect, a grill system which can be adapted for use with multiple sizes of register boxes is provided. The grill system includes a grill funnel configured to be attached to a register box, the grill funnel having a body with an airflow pathway that includes an airflow opening and a plurality of secondary airflow openings, wherein the secondary airflow openings are initially closed. The grill system further includes a grill assembly having a plurality of airflow adjustment members for controlling the airflow through the airflow pathway, wherein the grill assembly is attached to the grill funnel. In another aspect, a method of using a grill system is provided. In yet a further aspect, a grill funnel for use with a register box and a grill is provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. provisional patent applicationSer. No. 61/169,573, filed Apr. 15, 2009, which is herein incorporatedby reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the present invention generally relate to heating,ventilating, and air-conditioning systems. More particularly, theinvention relates to the grills and register boxes which exist at thedistal ends of duct systems for delivering air into rooms served by theHVAC system.

2. Description of the Related Art

The typical air registers in commercial and residential settings consistof louvers which may be manually opened or closed in varying degrees.These air registers provide an ability to adjust the amount of airflowinto a room or area, the air coming from a central environmental controlunit, such as a furnace, central air-conditioner, or dehumidifier. Theremay be several such vents connected, via ducts, to the centralenvironmental control unit, each vent providing airflow to a room orarea. There are a wide variety of sizes of register boxes which areinstalled at the distal ends of these duct systems. These variations insize may be due to airflow requirements, local or regional buildingcodes, or individual preference by the builder. Typical register boxsizes may be 6×8, 6×10, 6×6, 6×12, and 6×14, 8×8, 8×10, 8×12, 8×14 oreven larger in industrial applications. The different sizes create aninventory problem for air-conditioning distributors and servicepersonnel. Not knowing in advance the sizes that may be in a specificinstallation can be problematic if the service vehicle happens not tohave the right size on board during a service call. The situation isworse for the air-conditioning distributor who must maintain a dozen ormore sizes in his warehouse.

An example of a typical register is illustrated in FIG. 1. As shown, aregister grill assembly 1 is permanently connected to an adjustable vanesystem 3 which protrudes into the register box (not shown). The vanesystem 3 is manually operated by a control lever 2 which is operativelyattached to the vane system 3. The nature of the design only allows thedevice to be utilized in a register box of specific size which isdetermined by the shape and volume of the vane system 3. One is requiredto carry inventory and multiple sizes in stock to cover the wide rangeof register boxes found in homes and businesses. Therefore, there is aneed for a single-size register grill unit which can service multiplesizes of register boxes.

SUMMARY OF THE INVENTION

The present invention is generally directed to an apparatus and methodfor providing a single-size register grill system. In one aspect, agrill system which can be adapted for use with multiple sizes ofregister boxes is provided. The grill system includes a grill funnelconfigured to be attached to a register box, the grill funnel having abody with an airflow pathway that includes an airflow opening and aplurality of secondary airflow openings, wherein the secondary airflowopenings are initially closed. The grill system further includes a grillassembly having a plurality of airflow adjustment members forcontrolling the airflow through the airflow pathway, wherein the grillassembly is attached to the grill funnel.

In another aspect, a method of using a grill system is provided. Themethod includes the step of providing the grill system that includes agrill assembly and a grill funnel, the grill funnel having a body withan airflow pathway that includes a primary airflow opening and aplurality of secondary airflow openings that are initially closed. Themethod further includes the step of determining a size of an opening ina register box. The method also includes the step of removing a bypassplug in at least one secondary opening if the size of the opening in theregister box is greater than the primary airflow opening in the grillfunnel. Additionally, the method includes the step of attaching thegrill system to the register box.

In yet a further aspect, a grill funnel for use with a register box anda grill is provided. The grill funnel includes a body having anadjustable airflow pathway that includes a primary airflow opening and aplurality of secondary airflow openings. Additionally, the grill funnelincludes a plurality of bypass plugs disposed in the secondary airflowopenings, wherein the bypass plugs are configured to block airflowthrough the secondary airflow openings and wherein the bypass plugs areremovable to adjust the size of the airflow pathway.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the presentinvention can be understood in detail, a more particular description ofthe invention, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 shows a register grill;

FIG. 2 shows a grill funnel for a grill system;

FIG. 3 shows the grill funnel with inner bypass plugs removed;

FIG. 4 shows the grill funnel with both the inner and outer bypass plugsremoved;

FIG. 5 shows a front grill assembly of the grill system;

FIG. 6 shows the interior of the grill assembly showing internalmechanisms for airflow control;

FIG. 7 shows the details of a vane closure system and a control knobinside a grill assembly;

FIG. 8 shows a perspective view illustrating the grill system with aflow control unit;

FIG. 9 shows a perspective view illustrating the front of a grill systemin accordance with an embodiment of the invention.

DETAILED DESCRIPTION

The present invention is generally directed to an apparatus and methodfor providing a single-size register grill system which can servicemultiple sizes of register boxes. The present invention is essentially aone-size-fits-all register. It provides a variable opening into theregister box which can be configured at installation. Additionally, itmay provide for adjustable flow via a series of moveable vanes orshutters which are external to the register box. By placing all thesecomponents external to the register box, the size of the register boxbecomes of less significance. Various terms as used herein are definedbelow. To the extent a term used in a claim is not defined below, itshould be given the broadest definition persons in the pertinent arthave given that term, as reflected in printed publications and issuedpatents. In the description that follows, like parts are markedthroughout the specification and drawings with the same numberindicator. The drawings may be, but are not necessarily to scale, andthe proportions of certain parts have been exaggerated to betterillustrate details and features of the invention. One of ordinary skillin the art of a heating, ventilating, and air-conditioning system willappreciate that the embodiments of the invention can and may be used invarious types of flow systems. To better understand the novelty of thepresent invention and the methods of use thereof, reference is hereaftermade to the accompanying drawings.

FIG. 2 shows a grill funnel 10 which forms a back portion of a grillsystem 50. Generally, the grill system 50 includes a grill funnel 10 anda grill assembly 20 (see FIG. 5). The grill funnel 10 includes anairflow pathway that is adjustable. The grill funnel 10 is configured toattach a register box (not shown). The grill funnel 10 includes aprimary opening 14 (e.g., airflow opening) that is configured to be theairflow pathway through the grill funnel 10. The primary opening 14 isgenerally sized for a minimum register box dimension for which the grillsystem 50 may be used. The grill funnel 10 further includes a pluralityof secondary openings 15. The secondary openings 15 are closed by innerand outer bypass plugs 11, 12 which may be removed to increase the sizeof the airflow pathway through the grill funnel 10 to accommodate largerregister boxes than the primary opening 14. The bypass plugs 11, 12 maybe made from an elastomeric material or a composite material.

The grill funnel 10 includes a series of mounting holes 16 presentaround the periphery of the primary opening 14 which may be used tomount an optional automated flow control units as described in U.S. Pat.No. 7,347,774, which is incorporated herein by reference. In anotherembodiment, the grill funnel 10 may be used with conventional grillswhich have a user adjustable closure system.

FIG. 3 shows the grill funnel 10 with several inner bypass plugs 12removed. The removal of the inner bypass plugs 12 effectively increasesthe size of the airflow pathway (e.g., opening) between the grill funnel10 to the register box (not shown). For example, if the primary opening14 was 6×10 inches, then with the inner bypass plugs 12 removed suchthat the secondary openings 15 are opened, the grill funnel 10 wouldhave an airflow pathway that would be suitable for a larger size such as6×12 inches.

FIG. 4 shows the grill funnel 10 with the bypass plugs 11, 12 removed.As a result, the effective opening (e.g., airflow pathway) to theregister box is enlarged by exposing each secondary openings 15. Theholes 19 are drilled at specific intervals to allow the connection ofgrill funnel 10 to the ceiling or wall register box during installation.This allows this example grill funnel 10 to service register boxes from6×10 through 6×14. The example of removable bypass plugs is only one wayin which to vary the effective opening of the grill funnel 10. Alternateembodiments include but are not limited to sliding doors, roll up gates,folding gates (accordion style), pre-molded punch out plugs, etc.

FIG. 5 shows the front view of the grill assembly 20 of the grill system50. The grill assembly 20 is configured to be attached to the grillfunnel 10 (see FIG. 1). The grill assembly 20 includes a housing with aseries of vertical and horizontal vanes 21, 22 to deflect the airflowuniformly into the room served. In other words, the vanes 21, 22 areconfigured to direct air flowing through the airflow pathway. Alsovisible in FIG. 5 is an adjustment knob 25 which may be used to controlthe airflow through the grill system 50.

FIG. 6 a shows the inside of the grill assembly 20. For clarity, thegrill funnel is not shown. Mounted on the grill assembly 20 arecorresponding airflow adjustment members 23, 24 such as vertical andhorizontal shutters which may be used to vary the airflow through thegrill assembly 20. The adjustment members 23, 24 are activated by meansof the adjustment knob 25 which is operatively connected to theadjustment members 23, 24.

FIG. 6 b shows a cross-section view of the grill assembly 20. As shownin FIG. 6 b, the vertical vanes 21 line up with vertical adjustmentmembers 23 to form a means to regulate airflow through the grillassembly 20.

FIG. 7 illustrates an enlarged view of the adjustment knob 25. In oneembodiment, the adjustment knob 25 is connected to the adjustmentmembers 23, 24 by connection members 27, such as rods, linkages or cablearrangement. One portion of the connection member 27 is attached to theadjustment knob 25, and another portion of the connection member 27 isattached to the adjustment members 23, 24. Rotating the adjustment knob25 between a first position and a second position causes the connectionmembers 27 to move, and hence each adjustment member 23, 24 to pivotaround an end of the adjustment member 23, 24 to open or close off theairflow through the grill assembly 20.

FIG. 8 shows an embodiment of the grill system 50 used in conjunctionwith an optional flow control device 30. An example of a flow controldevice is described in U.S. Pat. No. 7,347,774. The flow control device30 is attached to the back of the grill funnel 10 by attachment members(not shown), such as screws. The removable bypass plugs have beenremoved in this view. In operation, one might remove these to reduce theamount of airflow through the flow control unit should excessive airflowbe present and the airflow control unit is smaller than the register boxto which it is to be inserted. In this manner it is possible to servicea wide range of register boxes and airflow rates with a limited numberof sizes of grill assemblies and airflow control units. Also shown inthis view is a seal assembly 18 which is attached to the wall or ceilingcontacting face of grill funnel 10. This serves to seal the airflow andprevent flow-out from the edges of the grill assembly which can discolora wall or ceiling over time. Alternately, the seal assembly may be heldin a groove formed into the grill funnel 10. Again, in this view themounting holes 19 are visible. Operationally, the installer selects theholes 19 to match the register box size to which the grill assembly isaffixed (not shown). In one embodiment, the grill system 50 extends froman end of the register box.

FIG. 9 illustrates a grill system 60 in accordance with one embodimentof the invention. For convenience, the components in the grill system 60that are similar to the components in the grill system 50 will belabeled with the same number indicator. The grill system 60 includes thegrill assembly 20 and the grill funnel 10. The grill system 60optionally may include the flow control device 30. In this embodiment,the vanes 21 are separated by a divider 31. As shown in FIG. 9, thedivider 31 is positioned at an angle relative to the sides of the grillassembly. In the case of a smaller register box, the horizontal andvertical grill vane structure, as shown in FIG. 5, may not be aseffective in distributing air into the room because the lateral vanesmay not be in the main airflow. In the embodiment shown in FIG. 9, theface of the grill is divided into three airflow directions, and theangle of the separation divider 31 is designed to give a more uniformflow in all three directions without regard to the register box size orthe number of bypass plugs removed.

Although the descriptions above contain many specifications, theseshould not be construed as limiting the scope of the invention but asmerely providing illustrations of some of the embodiments of thispresent invention. Persons skilled in the art will understand that themethod and apparatus described herein may be practiced, including butnot limited to, the embodiments described. Further, it should beunderstood that the invention is not to be unduly limited to theforegoing, which has been set forth for illustrative purposes. Variousmodifications and alternatives will be apparent to those skilled in theart without departing from the true scope of the invention, as definedin the following claims. While there have been illustrated and describedparticular embodiments of the present invention, it will be appreciatedthat numerous changes and modifications will occur to those skilled inthe art, and it is intended in the appended claims to cover thosechanges and modifications which fall within the true spirit and scope ofthe present invention.

While the foregoing is directed to embodiments of the present invention,other and further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

1. A grill system which can be adapted for use with multiple sizes ofregister boxes, the grill system comprising: a grill funnel configuredto be attached to a register box, the grill funnel having a body with anairflow pathway that includes an airflow opening and a plurality ofsecondary airflow openings, wherein the secondary airflow openings areinitially closed; and a grill assembly having a plurality of airflowadjustment members for controlling the airflow through the airflowpathway, wherein the grill assembly is attached to the grill funnel. 2.The grill system of claim 1, wherein a bypass plug is disposed in eachsecondary airflow opening.
 3. The grill system of claim 2, wherein eachbypass plug is removable to increase the size of the airflow pathway. 4.The grill system of claim 1, wherein the adjustment members are a set ofshutters that are connected to an adjustment knob.
 5. The grill systemof claim 4, wherein the rotation of the adjustment knob causes eachshutter to pivot around an end of the shutter to control the amount ofairflow through the airflow pathway.
 6. The grill system of claim 1,wherein the grill funnel includes a seal assembly that is configured tocreate a seal with the register box.
 7. The grill system of claim 6,wherein the seal assembly is disposed in a groove formed in the grillfunnel.
 8. The grill system of claim 1, wherein the grill funnelincludes a plurality of holes for attaching a flow control device. 9.The grill system of claim 1, wherein the grill assembly further includesa housing with at least a first side and a second side and wherein thehousing includes a plurality of vanes that are configured to direct airmoving through the airflow pathway.
 10. The grill system of claim 9,wherein each of the vanes are substantially parallel to at least oneside of the housing.
 11. The grill system of claim 9, wherein each ofthe vanes are disposed in the housing at an angle relative to the atleast one side of the housing.
 12. A method of using a grill system, themethod comprising: providing the grill system, the grill systemincluding a grill assembly and a grill funnel having a body with anairflow pathway that includes a primary airflow opening and a pluralityof secondary airflow openings that are initially closed; determining asize of an opening in a register box; removing a bypass plug in at leastone secondary opening if the size of the opening in the register box isgreater than the primary airflow opening in the grill funnel; andattaching the grill system to the register box.
 13. The method of claim12, further comprising rotating an adjustment knob in the grill assemblyto control the amount of air moving through the airflow pathway.
 14. Agrill funnel for use with a register box and a grill, the grill funnelcomprising: a body having an adjustable airflow pathway that includes aprimary airflow opening and a plurality of secondary airflow openings;and a plurality of bypass plugs disposed in the secondary airflowopenings, wherein the bypass plugs are configured to block airflowthrough the secondary airflow openings and wherein the bypass plugs areremovable to adjust a size of the airflow pathway.
 15. The grill funnelof claim 14, further comprising a sealing assembly disposed in a grooveformed in the body.